Device for use in a carton or container holding a flanged window frame

ABSTRACT

A precursor for forming a spacer and the spacer itself for protecting and holding a window frame within a carton or container. The window frame includes a flange. The precursor is a generally planar blank of corrugated paper having plural fold lines to facilitate the folding of the blank to form the spacer. The spacer has an elongated body having a first side and a second side opposed to each other. The first side includes a recess formed by confronting portions of the blank and is arranged to receive a portion of the flange of the window frame therein. The second side of the elongated spacer body is arranged to closely engage an adjacent interior surface of the carton or container.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to packages (e.g., cartons) for window frames and more particularly to devices for holding flanged window frames within packages to protecting such window frames.

2. Description of Related Art

Various packages or containers, such as corrugated paper cartons, are commonly used for holding window frames for delivery to the building in which the frame is to be installed. Such cartons typically make use of one or more foam members which are shaped to fill up space(s) between portion(s) of the window frame and portion(s) of the container or package holding the window frame so that it is held securely and cannot shift or move about. Moreover, by being spaced inward from the walls of the carton, the chances of impact induced damage to the window frame are reduced should the carton be dropped or impacted in some manner. In lieu of foam spacers, sometimes spacers formed of single or multiple layers of corrugated paper are used, depending upon the distance the window frame is to be located from the walls of the carton or container holding it.

In addition to the items identified above, the patent literature also includes disclosures of packages or devices for holding windows and window frames. See for example, U.S. Pat. No. 3,618,755 (Kean Sr.), U.S. Pat. No. 4,583,639 (Fedick), U.S. Pat. No. 5,174,448 (Flaig), U.S. Pat. No. 5,605,229 (Sowa) and U.S. Pat. No. 6,276,526 (Miller et al.).

While the above described prior art devices for holding windows/window frames appear generally suitable for their intended purposes, they still leave something to be desired from one or more standpoints. For example, inserts in the form of blocks are rather bulky and thus an inventory of such inserts can take up considerable space in a warehouse or factory. Moreover, once the window frame has been delivered and unpacked from its carton, the carton and the spacers have to be discarded. In the case of foam inserts/spacers, this can present environmental issues.

Thus, a need exists for a spacer for a window frame which is formed of an environmentally acceptable, e.g., degradable and/or reusable, material, and which can be stored in a compact condition until it is ready to be used, whereupon it can be configured, e.g., unfolded, into an operative state.

BRIEF SUMMARY OF THE INVENTION

In accordance with one aspect of this invention there is provided a precursor for forming a spacer and the spacer itself for protecting and holding a window frame within a carton or container. The window frame includes a flange extending along at least a portion of the periphery thereof. The carton or container has plural wall portions, each of which includes an inner surface. The window frame is disposed within the carton or container so that a portion of the flange is spaced from an immediately adjacent and juxtaposed interior surface of the carton or container.

The precursor comprises a first generally planar blank of corrugated paper having plural fold lines therein constructed to facilitate the folding of the blank along respective ones the fold lines, whereupon the blank forms the spacer. The spacer has an elongated spacer body having a first side and a second side. The first and second sides are opposed to each other. The first side includes a recess formed by confronting portions of the blank. The recess is arranged to closely receive a portion of the flange of the window frame therein. The second side of the elongated spacer body is arranged to closely engage the adjacent interior surface of the carton or container to facilitate the holding of the window frame at a predetermined position within the carton or container while protecting the flange of the window frame.

In accordance with one preferred embodiment of the invention the precursor includes a second, third and fourth blank constructed like the first blank, with the first second, third and fourth blanks being releasably secured to one another and arrange to be separated to form respective spacers. Each blank has a generally rectangular or square shape having a first side edge, a second side edge, a third side edge and a fourth side edge. The first side edge is disposed opposite and generally parallel to the third side edge. The second side edge is disposed opposite and generally parallel to the fourth side edge. The fold lines extend generally parallel to the first and third side edges and comprise a sequence of fold lines comprising a first fold line, a second fold line, a third fold line, a fourth fold line, a fifth fold line, a sixth fold line and a seventh fold line. The sequence of fold lines start adjacent the first side edge of the blank and terminate adjacent the third side edge of the blank.

In accordance with another aspect of this invention one portion of each blank is arranged to include an adhesive thereon for securing it to another portion of the blank so that when the blank is folded the one portion of that blank cannot move with respect to the other portion of that blank. Moreover, at least one tab is provided along the third side edge of each blank to project therefrom and at least one slot is provided along the first fold line. The at least one tab is arranged to reside within the at least one slot when the precursor is folded to form the spacer.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:

FIG. 1 is a top plan view of a conventional, e.g., corrugated paper, carton holding a conventional replacement window frame therein by means of four spacers constructed in accordance with this invention;

FIG. 2 is a top plan view of a blank of corrugated paper in the form of four interconnected, but separable blanks, each of which serves as a precursor for creating the four spacers shown in FIG. 1;

FIG. 3 is an isometric view of one portion of the spacer shown in the lower right corner of the carton shown in FIG. 1, showing the spacer engaging and protecting a flange of the window frame;

FIG. 4 is an isometric view of a portion of any of the spacers shown in FIG. 1 ready to engage an adjacent portion of the flange of the window frame, which window frame and flange is shown by phantom lines; and

FIG. 5 is an enlarged sectional view of taken along lines 5-5 of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

Referring now in greater detail to the various figures of the drawing, wherein like reference characters refer to like parts, a set of four inserts or spacers embodying the present invention are generally shown at 20 in FIG. 1. The set 20 of spacers is arranged to hold a conventional flanged window frame 22 within a carton or box 24 so that the window frame is protected and doesn't shift or otherwise move during storage or transportation and in addition to hold the window frame somewhat spaced from the walls of the carton to reduce the risk of damage to the window frame if the carton 24 is impacted. The set 20 of spacers comprises four spacers 20A, 20B, 20C and 20D. It should be pointed out at this juncture that the number of spacers used for any window frame/carton combination depends upon the shape and size of the window and the shape and size of the carton. Thus, since the exemplary window frame shown in FIG. 1 is rectangular, as is the carton 24, four spacers are used. For other shaped windows, e.g., Palladian, round, oval, any suitable number of spacers may be used, with the length of the spacer being a function of the size and/or curvature of the portion of the window frame to which it will be engaged.

Before describing the details of the spacers 20A-20D, a brief description of the window frame 22 and the carton 24 is in order. Thus, the window frame 22 is a conventional component that includes, in the exemplary embodiment of FIG. 1, a rectangular frame made up of four sides 22A, 22B, 22C and 22D surrounding and holding a glass pane 28. Those sides are interconnected and formed of any conventional material, e.g., aluminum, wood, etc. A thin flange 26 projects outward from the outside edge of each of the frame's sides and may extend along the entire length of that side or only along a portion of it. The flange 26 is typically formed of a metal, e.g., aluminum, even if the window frame itself is formed of some other material, e.g., wood. The flange is used as a means for mounting and securing the window frame into the opening of the building (not shown) or other structure (not shown) in which the window is to be located. The window frame can be any size. In the example illustrated its jamb is 4.25 inches (10.8 cm) thick, the flange is 2 inches (5.1 mm) wide, and the flange is ⅛ inch (3.2 mm) thick. This is merely exemplary. Inasmuch as the flange is a somewhat thin component, it is of considerable importance to protect it from damage, since such action could adversely affect the ability of the window frame to be appropriately mounted in the opening for the window.

The carton 24 is also a conventional component that is formed of any conventional material, e.g., corrugated paper. It includes, in the exemplary embodiment of FIG. 1, a first side wall 24A, a second side wall 24B, a third side wall 24C, a fourth side wall 24D, a bottom wall 24E, and a top wall 24F (only a portion of which can be seen). The side walls 24A-24D form the periphery of the carton, whereupon a hollow interior results between the inner surfaces of the peripheral side walls 24A-24D and the bottom wall 24E. It is in this hollow interior that the window frame is to be located, i.e., the window frame is disposed on the bottom wall, and is held in that position by the set 20 of spacers 20A-20D. In the embodiment shown the top wall 24 is hingedly connected to the side wall 24C and is arranged to be folded over the interior of the carton to enclose the window frame 22 therein. Preferably the top wall includes a peripheral flange or lip (not shown) which when the top wall is folded over the hollow interior of the carton engages the outer surface of the peripheral sidewalls 24A-24D. Alternatively, the top wall and its peripheral flange or lip may be a separate component not hingedly secured to the wall.

Turning now to FIG. 2 the details of a blank 30 of corrugated paper for forming the precursors of the spacers 20A-20D will now be described. That blank comprises conventional corrugated paper, but could be other materials as well. If corrugated paper is used it can have any suitable flute size and weight. One particularly suitable corrugated paper is flute 32 ect recycled KLA white 35-26-35. The blank 30 is a generally planar member made up of four generally rectangular blank sections 30A, 30B, 30C and 30D which are interconnected to one another via perforated or other frangible lines 32 and 34 which extend perpendicularly to each other. The perforated line 32 also includes a series of narrow elongated slots or recesses 36 located therealong. Once the sections 30A, 30B, 30C and 30D are separated from one another by breaking the perforated lines 32 and 34 each section forms a precursor blank from which a respective spacer can be formed. The formation of a spacer from a blank will be described in detail later. Suffice it for now to state that such action is accomplished by merely folding the blank along fold lines (to be described later) in the blank. The portions of the blanks contiguous with the perforated line 32 that is located between the recesses 36 form tabs (to be described later) when the blanks are separated from each other. These tab cooperate with slots or recesses (also to be described later) in other portions of the blank when the blank is folded to form a spacer 20A-20D. The blanks 30A and 30B form precursors for two longer spacers 20A and 20B, while the blanks 30A and 30B form precursors for two shorter spacers 20C and 20D. Except for their length the spacers 20A-20D are of essentially the same construction.

The details of the blanks or sections 30A and 30B will now be described. As can be seen each is of a generally rectangular shape (but could be a square) and includes a first side edge 38, a second side edge which constitutes the perforated line 34, a third side edge which constitutes the perforated line 32, and a fourth side edge 42. The first side edge 38 of the first blank 30A is disposed opposite and generally parallel to the third side edge 32 of the first blank. The second side edge 34 of the first blank 30A is disposed opposite and generally parallel to the fourth side edge 42 of the first blank. In a similar manner the first side edge 38 of the second blank 30B is disposed opposite and generally parallel to the third side edge 32 of the second blank. The second side edge 34 of the second blank 30B is disposed opposite and generally parallel to the fourth side edge 42 of the second blank. With respect to the blanks 30C and 30D, each is also of a generally rectangular shape (but could be a square). Each includes a first side edge 38, a second side edge which constitutes the perforated line 34, a third side edge which constitutes the perforated line 32, and a fourth side edge 44. The first side edge 38 of the third blank 30C is disposed opposite and generally parallel to the third side edge 32 of the third blank. The second side edge 34 of the third blank 30A is disposed opposite and generally parallel to the fourth side edge 44 of the third blank. In a similar manner the first side edge 38 of the fourth blank 30D is disposed opposite and generally parallel to the third side edge 32 of the fourth blank. The second side edge 34 of the fourth blank 30B is disposed opposite and generally parallel to the fourth side edge 44 of the fourth blank. Thus, the first blank 30A is releasably connected to the second blank 30B and the third blank 30C by perforated lines 32 and 34, respectively. The second blank 30B is releasably connected to first blank 30A and the fourth blank 30D by perforated lines 32 and 34, respectively. The third blank 30C is releasably connected to the first blank 30A and the fourth blank 30D by perforated lines 34 and 32, respectively. The fourth blank 30D is releasably connected to the second blank 30B and the third blank 30C by perforated lines 34 and 32, respectively.

Each of blanks 30A-30D includes seven, parallel, linear fold lines 46, 48, 50, 52, 54, 56 and 58. The fold lines are disposed parallel to the first and third sides of each of the blanks and when any of the blanks is folded along its fold lines it forms a respective spacer (as will be described later). The fold lines of each blank are in the sequence of 46, 48, 50, 52, 54, 56 and 58, with the fold line 46 being located closest to the first side of its blank and with the fold line 58 being located closest to the third side of its blank. The spacing of the fold lines such as shown herein is merely exemplary to provide a spacer for a carton holding a window frame like that shown herein. Thus, depending upon the location and size of the flange 26 of the window frame and on the size of the spacer desired, the spacing between the fold lines can be selected as desired.

As mentioned earlier the portions of the blanks contiguous with the perforated line 32 that is located between the recesses 36 form tabs when the blanks are separated. Those tabs are identified by the reference number 60. In the embodiment shown there are three such tabs on the third side edge of the blank 30A and three such tabs on the third side edge of the blank 30B. The tabs are equidistantly spaced from each, with the middle tab being located centrally between the other two tabs. Blanks 30C and 30D have two tabs 60. A plurality of slots 62 are located immediately adjacent the first fold line 46 of each of the blanks 30A-30D. The slots 62 are aligned with the tabs 60 and each slot is of a length sufficient to receive therein a respective tab 60 when the blank is folded up to form the spacer as will be described hereinafter.

Referring now to FIGS. 4 and 5 the formation of a spacer from one of the precursor blanks will now be described. In the interest of expediency only the formation of one of the spacers, namely, long spacer 20A will be described, since the formation of each of the other spacers 20B-20C is accomplished in the same manner. Thus, as can be seen the blank 30A is folded up by folding it along first fold line 46 to form an inside corner and is folded along the second, third, fourth, fifth, sixth and seventh fold lines 48, 50, 52, 52, 56 and 58, respectively, to form respective outside corners. This action brings the portion of the outer surface of the blank 30A between the third side edge 32 and the portion of the outer surface of the blank 30A between the first and second fold lines 46 and 48, respectively, into a confronting relationship. The tabs 60 along the third side edge 32 enter into their respective slots 62 in the first fold line 46, whereupon a slot or recess 64 (FIG. 5) is produced between the confronting surfaces. The slot 64 is arranged to receive the flange 26 of the window frame 22 when the spacer is brought into engagement with it (as will be described later). In order to hold the blank in its folded up condition an adhesive layer 66 is located at the interface of the inner surface of the blank 30A between its first side edge 38 and the first fold line 46 as best seen in FIG. 5.

The completed spacer 20A thus is an elongated body having a generally planar exterior side 68, which if desired, may include indicia 70 thereon. The indicia may constitute product identification materials, trademarks, installation and/or use instructions, etc., that is printed on the outer surface of the blank. The interior side of the spacer 20A is designated by the reference number 72 and is the portion arranged to about the exterior surface of the window frame to which the spacer is releasably connected. In the embodiment shown the interior side of the spacer is of a stepped configuration to engage respective portions of the periphery of the window frame on opposite sides of its projecting flange 26, with the flange residing within the slot 64 of the spacer.

Once all of the blanks have been folded to form the set of spacers 20, the spacers 20A-20D are ready for use to hold a window frame 22 within the interior of the carton 24. To accomplish that end the long spacer 20A is releasably secured to the lower right hand side of the window frame by abutting its interior surface 72 against the exterior surface of the window frame and with the flange 26 received within the slot 64. The other long spacer 20B is similarly releasably secured to the lower left hand side of the window frame in an identical manner. Once those two spacers have been positioned as just described at least one (in the exemplary embodiment shown, two) conventional plastic wrapping bands 74 are wrapped about those spacers and the interposed window frame to securely hold the spacers onto the window frame. The two short spacers 30C and 30D are releasably secured to the upper left hand and upper right hand portions, respectively, of the window frame and are held in place by a single wrapping band 74. The window frame with the spacers 20A-20D now secured thereto can then be introduced into the interior of the carton, whereupon the outer surfaces 70 of those spacers 20A-20D engage respective inner surfaces of the side walls of the carton.

If desired, other spacer members like those of the prior art may also be used. To that end in the exemplary embodiment shown herein a plurality of multilayered corrugated blocks 76 maybe provided, with each block having a slot 78 (FIG. 3) for receiving a portion of the window frame flange therein.

As should be appreciated by those skilled in the art, the precursors of the subject invention are simple in construction and low in cost. Moreover, and quite significantly they are compact so that they can be stored expeditiously until needed. When needed they can be readily configured into spacers by merely folding them along their fold lines, thereby resulting in a spacer having the attributes of a solid bodied member, but without any attendant space wasting attributes. Moreover, if the spacers are constructed of corrugated paper they can be readily disposed of without adverse environmental consequences or may be re-manufactured or reclaimed. By forming a blank containing plural precursors which can be readily separated from one another, one provides a convenient means for creating a set of spacers. It should be pointed out that the precursor blank can be made of only one precursor for forming only a single spacer.

While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. 

1. A precursor for a spacer for protecting and holding a window frame within a carton or container, the window frame including a flange extending along at least a portion of the periphery thereof, the carton or container having plural wall portions, each of which includes an inner surface, the window frame being disposed within the carton or container so that a portion of the flange is spaced from an immediately adjacent and juxtaposed interior surface of the carton or container, said precursor comprising a first generally planar blank of corrugated paper having plural fold lines therein constructed to facilitate the folding of said blank along respective ones said fold lines, whereupon said blank forms said spacer, said spacer having an elongated spacer body having a first side and a second side, said first and second sides being opposed to each other, said first side including a recess formed by confronting portions of said blank, said recess being arranged to closely receive a portion of the flange of the window frame therein, said second side of said elongated spacer body being arranged to closely engage the adjacent interior surface of the carton or container to facilitate the holding of the window frame at a predetermined position within the carton or container while protecting the flange of the window frame.
 2. The precursor of claim 1 wherein one portion of said blank is arranged to include an adhesive thereon for securing it to another portion of said blank so that when said blank is folded said one portion of said blank cannot move with respect to said other portion of said blank.
 3. The precursor of claim 1 wherein said blank has a generally rectangular or square shape having a first side edge, a second side edge, a third side edge and a fourth side edge, said first side edge being disposed opposite and generally parallel to said third side edge, said second side edge being disposed opposite and generally parallel to said fourth side edge, said fold lines extending generally parallel to said first and third side edges.
 4. The precursor of claim 3 wherein said fold lines comprise a sequence of fold lines comprising a first fold line, a second fold line, a third fold line, a fourth fold line, a fifth fold line, a sixth fold line and a seventh fold line, said sequence of fold line starting adjacent said first side edge of said blank and terminating adjacent said third side edge of said blank.
 5. The precursor of claim 4 wherein said one of said confronting portions of said blank forming said recess is the portion of said blank between said first fold line and said second fold line, and wherein the other of said confronting portions of said blank forming said recess is the portion of the blank between said seventh fold line and said third edge.
 6. The precursor of claim 1 comprising plural blanks constructed like said first blank, said plural blanks being releasably secured to one another and arranged when separated and folded to form respective spacers.
 7. The precursor of claim 4 comprising plural blanks constructed like said first blank, said plural blanks being releasably secured to one another and arranged when separated and folded to form respective spacers, and wherein at least one of the portion of each of said blanks between said first side edge and said first fold line and the portion of said blank between said fourth fold lines and said fifth fold line is arranged to include an adhesive thereon so that when said blank is folded said portion of said blank between said first side edge and said first fold line and said portion of said blank between said fourth fold lines and said fifth fold line cannot move with respect to each other.
 8. The precursor of claim 4 comprising plural blanks constructed like said first blank and wherein said plural blanks comprise first, second, third and fourth blanks releasably secured to one another and arranged when separated and folded to form respective spacers.
 9. The precursor of claim 8 wherein said third side edge of said first blank is releasably secured to said third side edge of said second blank by a frangible or otherwise severable line, said third side edge of said third blank is releasably secured to said third side edge of said fourth blank by a frangible or otherwise severable line, said second side edge of said first blank is releasably secured to said second side edge of said third blank by a frangible or otherwise severable line, and said second side edge of said fourth blank is releasably secured to said second side edge of said second blank by a frangible or otherwise severable line.
 10. The precursor of claim 9 wherein at least one of the portion of each of said blanks between said first side edge and said first fold line and the portion of said blank between said fourth fold line and said fifth fold line is arranged to include an adhesive thereon so that when said blank is folded said portion of said blank between said first side edge and said first fold line and said portion of said blank between said fourth fold lines and said fifth fold line cannot move with respect to each other.
 11. The precursor of claim 9 wherein the distance between said second side edge and said fourth side edge of said third and fourth blanks is shorter than the distance between said second side edge and said fourth side edge of said first and second blanks.
 12. The precursor of claim 1 wherein said spacer includes an inner surface and an outer surface and wherein said outer surface includes visible indicia thereon.
 13. The precursor of claim 1 wherein said third side edge includes a tab projecting therefrom and wherein a portion of said first blank adjacent said first edge includes a slot arranged to receive said tab.
 14. The precursor of claim 5 wherein said third side edge includes a tab projecting therefrom and wherein a said first fold line includes a slot arranged to receive said tab.
 15. A spacer for protecting and holding a window frame within a carton or container, the window frame including a flange extending along at least a portion of the periphery thereof, the carton or container having plural wall portions, each of which includes an inner surface, the window frame being disposed within the carton or container so that a portion of the flange is spaced from an immediately adjacent and juxtaposed interior surface of the carton or container, said spacer being formed of a blank of corrugated paper folded along respective fold lines to produce an elongated spacer body having a first side and a second side, said first and second sides being opposed to each other, said first side including a recess formed by confronting portions of said blank, said recess being arranged to closely receive a portion of the flange of the window frame therein, said second side of said elongated spacer body being arranged to closely engage the adjacent interior surface of the carton or container to facilitate the holding of said window frame at a predetermined position within the carton or container while protecting the flange of the window frame.
 16. The spacer of claim 15 wherein one portion of said blank is secured securing it to another portion of said blank so that said one portion of said spacer cannot move with respect to said other portion of said spacer.
 17. The spacer of claim 19 wherein said fold lines comprise a sequence of parallel fold lines comprising a first fold line, a second fold line, a third fold line, a fourth fold line, a fifth fold line, a sixth fold line and a seventh fold line and wherein said first fold line forms an inner corner, and said second, third, fourth, fifth, sixth and seventh fold lines form respective outer corners.
 18. The spacer of claim 17 wherein said one of said confronting portions of said blank forming said recess is the portion of said blank between said first fold line and said second fold line, and wherein the other of said confronting portions of said blank forming said recess is the portion of the blank between said seventh fold line and said third edge.
 19. The spacer of claim 18 wherein said blank includes a first side edge, said first fold line being located adjacent said first side edge and wherein the portion of said blank between said first side edge and said first fold line is secured to a portion of said blank between said fourth and fifth fold lines, so that said secured portions cannot move with respect to each other.
 20. The spacer of claim 15 wherein said spacer includes an exterior surface bearing indicia.
 21. The spacer of claim 18 wherein said blank includes a third side edge located adjacent said seventh fold line, wherein said third side edge includes a tab projecting therefrom and wherein a said first fold line includes a slot receiving said tab. 